Direct-current aircraft cable connector and preparation method thereof

Abstract

The invention provides a direct-current aircraft cable connector and a preparation method thereof, and relates to the technical field of electrical elements, the direct-current aircraft cable connector comprises a direct-current remote control plug and a direct-current remote control cable, and the direct-current remote control plug is connected with the direct-current remote control cable; the direct-current remote control plug comprises a plug seat, a plug shell is arranged on the plug seat, a positive terminal, an auxiliary terminal and a negative terminal are arranged on the plug shell, and a control button and an indicator lamp are arranged at the end of the plug seat. A plurality of positive wire cores and a plurality of negative wire cores of the direct-current remote control cable are wrapped by a wrapping tape to form a first cable core group, a plurality of positive wire cores, a plurality of negative wire cores and a control wire core group are arranged outside the first cable core group, and the control wire core group, the positive wire cores and the negative wire cores are wrapped by a wrapping tape to form a second cable core group. The control wire cores are arranged among the power wire cores, the outer diameter of the cable is reduced, the carbon fibers are adopted as the filling cores, the wire breaking rate of the conductors is reduced, and the safety performance of the cable is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of electrical components, and in particular to a DC aircraft cable connector and a preparation method thereof. Background Art

[0002] With the rapid development of my country's modern economy, special occasions such as DC aircraft, car charging piles, and high-current test equipment require special cables. DC aircraft cables require high-current direct current when used, so the safety requirements for the temperature resistance level of the cable itself are very high. In addition, the cable is frequently retracted and moved, which places high demands on the cable's flexibility and the wire breakage rate after multiple bending. The cable's resistance to external tension in frequently moving occasions is very high. The cables produced by existing domestic technology have the following disadvantages: 1. The existing DC charging cables have poor bending resistance, flexibility, and tensile strength; 2. The existing DC aircraft cables have a small current carrying capacity; 3. The existing connectors have few control functions and are inconvenient to operate. Summary of the invention

[0003] The purpose of the present invention is to overcome the deficiencies in the prior art, provide a DC aircraft cable connector and a preparation method thereof, and improve the safety performance of the cable.

[0004] The technical solution adopted by the present invention is: A DC aircraft cable connector, wherein the DC aircraft cable connector comprises a DC remote control plug and a DC remote control cable, wherein one end of the DC remote control plug is connected to the DC remote control cable; The DC remote control plug comprises a plug socket, a plug shell, a positive terminal, an auxiliary terminal, a negative terminal, a control button, and an indicator light; the plug socket is provided with a plug shell, the positive terminal, the auxiliary terminal, and the negative terminal are provided on the plug shell, and the end of the plug socket is provided with a control button and an indicator light; The DC remote control cable includes a positive core, a control core group, a filling core, a tape, and a negative core; a plurality of positive cores and negative cores are wrapped with a tape to form a first cable core group, and a filling core is provided in the gaps between the plurality of positive cores and negative cores. A plurality of positive cores, a plurality of negative cores and a plurality of control core groups are arranged outside the first cable core group. Two groups of the plurality of control core groups are arranged on both sides of the outer periphery of the first cable core group. A positive core and a negative core are respectively arranged between the two groups of control core groups. The control core group, the positive core and the negative core are wrapped with a tape to form a second cable core group.

[0005] Preferably, in the DC aircraft cable connector, the number of auxiliary terminals is 8, and the number of control buttons and indicator lights is 4.

[0006] Preferably, in the DC aircraft cable connector, a sheath is provided outside the second cable core group, and the material of the sheath is a low-smoke halogen-free polyolefin material.

[0007] Preferably, in the DC aircraft cable connector, the control wire core group is composed of multiple control wire cores wrapped with tape and insulating rubber from the inside to the outside, the core filling material is carbon fiber, and the tape material is high-strength polyester tape.

[0008] Preferably, in the DC aircraft cable connector, the outer diameter of the control wire core group is the same as the outer diameters of the positive wire core and the negative wire core.

[0009] The present application also provides a method for preparing a DC aircraft cable connector, which comprises the following steps: Step S1. pre-cable the control cores into a control core assembly in a 0+4 structure, then wrap the control core assembly with a wrapping tape, and then extrude insulating rubber outside the wrapping tape through a continuous vulcanization rubber extruder to form a control core group; Step S2. Wrap multiple positive electrode cores and multiple negative electrode cores with tape to form a first cable core group, and fill the center of the first cable core group with a filling core; cable multiple positive electrode cores, negative electrode cores and a control core group in a symmetrical manner, and distribute multiple positive electrode cores and multiple negative electrode cores on both sides of the control core group. Wrap the control core group, positive electrode cores and negative electrode cores with tape to form a second cable core group; Step S3. Extrude the sheath outside the second cable core group using a continuous sulfur rubber extrusion machine to obtain a DC remote control cable; Step S4. Disassemble the positive terminal, auxiliary terminal, negative terminal, control button, and indicator light of the DC remote control plug, cut the sheath of the DC remote control cable with a utility knife, and then connect multiple positive wire cores to the positive terminal of the DC remote control plug, and connect multiple negative wire cores to the negative terminal of the DC remote control plug, so that the DC remote control plug is connected to the power wire core of the DC remote control cable; Step S5. Connect the DC remote control plug to the control wire core of the DC remote control cable; Step S6. Install the positive terminal, auxiliary terminal, negative terminal, control button, and indicator light back onto the DC remote control plug; Step S7: Test the installed connector, and obtain a DC aircraft cable connector after passing the test.

[0010] Preferably, in the method for preparing the DC aircraft cable connector, step S5 is specifically: Step S51. Connect the control wire core of the DC remote control cable to the No. 1 terminal of the auxiliary terminal and the power indicator light to display the on / off status of the power supply; Step S52. Connect the control wire core of the DC remote control cable to the No. 2 terminal of the auxiliary terminal and the retractable indicator light to display the retractable status of the connector; Step S53. Connect the control wire core of the DC remote control cable to the No. 3 terminal of the auxiliary terminal and the in-place indicator light to display whether the connector is plugged in place; Step S54. Connect the control wire core of the DC remote control cable to the No. 4 terminal of the auxiliary terminal and the power button, and press it to control the power supply to be turned on; Step S55. Connect the control wire core of the DC remote control cable to the No. 5 terminal of the auxiliary terminal and the power-off button, and press it to disconnect the power supply; Step S56. Connect the control wire core of the DC remote control cable to the No. 6 terminal of the auxiliary terminal and the reeling button, and press it to control the reeling of the connector; Step S57. Connect the control wire core of the DC remote control cable to the No. 7 terminal of the auxiliary terminal and the release button, and press it to control the connector to release; Step S58. Connect the control wire core of the DC remote control cable to the No. 8 terminal of the auxiliary terminal as a common line.

[0011] Advantages of the present invention: The DC aircraft cable connector and the preparation method thereof of the present invention have a simple structure, a compact design, and are easy to use. The control wire core is arranged between the power wire cores, the outer diameter of the cable is reduced, and carbon fiber is used as the core filler, which can ensure that the cable can be used frequently and moved for a long time, and at the same time has excellent bending resistance, reduces the wire breakage rate of the conductor, and improves the safety performance of the cable. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a schematic structural diagram of the DC aircraft cable connector of the present invention.

[0013] Figure 2 It is a schematic structural diagram of a DC remote control plug of the present invention.

[0014] Figure 3 It is a structural schematic diagram of the DC remote control cable of the present invention.

[0015] Figure 4 The electrical schematic diagram of the DC aircraft cable connector of the present invention.

[0016] Explanation of the reference numerals: 1-DC remote control plug, 2-DC remote control cable, 1-1-plug socket, 1-2-plug housing, 1-3-positive terminal, 1-4-auxiliary terminal, 1-5-negative terminal, 1-6-control button, 1-7 indicator light, 2-1-positive core, 2-2-control core, 2-3-filling core, 2-4-wrapping tape, 2-5-negative core, 2-6-sheath. DETAILED DESCRIPTION

[0017] The present invention will be further described below in conjunction with specific drawings and embodiments.

[0018] Example 1 like Figure 1-3 , a DC aircraft cable connector, wherein the DC aircraft cable connector comprises a DC remote control plug 1 and a DC remote control cable 2, wherein one end of the DC remote control plug 1 is connected to the DC remote control cable 2; The DC remote control plug 1 comprises a plug socket 1-1, a plug shell 1-2, a positive terminal 1-3, an auxiliary terminal 1-4, a negative terminal 1-5, a control button 1-6, and an indicator light 1-7; the plug socket 1-1 is provided with a plug shell 1-2, the positive terminal 1-3, the auxiliary terminal 1-4, and the negative terminal 1-5 are provided with the plug shell 1-2, and the end of the plug socket 1-1 is provided with a control button 1-6 and an indicator light 1-7; the positive terminal 1-3 and the negative terminal 1-5 have the function of passing a large current, the number of the auxiliary terminals 1-4 is 8, the number of the control buttons 1-6 and the indicator lights 1-7 are both 4, the 8 auxiliary terminals 1-4 have the function of transmitting a control signal, the 4 control buttons 1-6 have the function of controlling the cable remote control cable retraction and power-off, and the 4 indicator lights 1-7 have the function of displaying the working status of the connector.

[0019] The DC remote control cable 2 includes a positive core 2-1, a control core group, a filling core 2-3, a wrapping tape 2-4, and a negative core 2-5; a plurality of positive cores 2-1 and negative cores 2-5 are wrapped with a wrapping tape 2-4 to form a first cable core group, and a filling core 2-3 is arranged in the gap between the plurality of positive cores 2-1 and negative cores 2-5. A plurality of positive cores 2-1, negative cores 2-5 and a plurality of control core groups are arranged outside the first cable core group. The plurality of control core groups are arranged in two groups on both sides of the outer periphery of the first cable core group. A positive core 2-1 and a negative core 2-5 are arranged between the two groups of control core groups, respectively. The control core group, the positive core 2-1 and the negative core 2-5 are wrapped with a wrapping tape 2-4 to form a second cable core group. A sheath 2-6 is arranged outside the second cable core group, and the material of the sheath 2-6 is a low-smoke halogen-free polyolefin material.

[0020] The control core group is composed of multiple control cores 2-2 wrapped from the inside to the outside with a wrapping tape 2-4 and insulating rubber. The control core 2-2 is formed by twisting multiple small control cores in groups. The core filling 2-3 is made of carbon fiber, and the wrapping tape 2-4 is made of a high-strength polyester tape with a smooth surface. The outer diameter of the control core group is the same as the outer diameter of the positive core 2-1 and the negative core 2-5.

[0021] The positive core 2-1 and the negative core 2-5 use category 5 copper wire twisted conductors, and the DC resistance of the conductors at 20°C meets the requirements of GB / T3956. The conductors are wrapped with polyester tape, and the polyester tape is wrapped with EPDM insulating rubber using a continuous sulfur extruder. The positive core 2-1 and the negative core 2-5 are distinguished by the color of the insulating layer, and the core surface is smooth and round; the control core 2-2 uses category 5 copper wire twisted conductors, and the DC resistance of the conductors at 20°C meets the requirements of GB / T3956.

[0022] Example 2 like Figure 1-3 , a method for preparing a DC aircraft cable connector, comprising the following steps: Step S1. The control core 2-2 is pre-cabled into a control core assembly in a 0+4 structure, and then the control core assembly is wrapped with a wrapping tape 2-4, and then the wrapping tape 2-4 is extruded with EPDM insulating rubber by a continuous vulcanization rubber extruder to form a control core group; the surface of the control core group is smooth and round, and the outer diameter of the extrusion is the same as that of the positive electrode core 2-1 or the negative electrode core 2-5; Step S2. Wrap multiple positive electrode cores 2-1 and multiple negative electrode cores 2-5 with a wrapping tape 2-4 to form a first cable core group, and fill the center of the first cable core group with a filling core 2-3; cable multiple positive electrode cores 2-1, negative electrode cores 2-5 and a control core group in a symmetrical manner, and distribute multiple positive electrode cores 2-1 and multiple negative electrode cores 2-5 on both sides of the control core group, and wrap the control core group, positive electrode cores 2-1, and negative electrode cores 2-5 with a wrapping tape 2-4 to form a second cable core group; Step S3. The outer sheath 2-6 of the second cable core group is extruded by a continuous sulfur extruder to obtain a DC remote control cable 2. The DC remote control cable 2 needs to undergo factory tests such as a finished conductor DC resistance test, a withstand voltage test, and an insulation resistance test, and is put into storage after the test is completed; Step S4. Disassemble the positive terminal 1-3, auxiliary terminal 1-4, negative terminal 1-5, control button 1-6, indicator light 1-7 of the DC remote control plug 1, and put all the parts in the same bag to prevent the parts from being lost; use a utility knife to cut the sheath 2-6 of the qualified DC remote control cable 2, and then connect multiple positive wire cores 2-1 to the positive terminal 1-3 of the DC remote control plug 1, and connect multiple negative wire cores 2-5 to the negative terminal 1-5 of the DC remote control plug 1, so that the DC remote control plug 1 is connected to the power wire core of the DC remote control cable 2; Step S5. Connect the DC remote control plug 1 to the control wire core of the DC remote control cable 2 by welding or crimping; Step S6. Install the positive terminal 1-3, the auxiliary terminal 1-4, the negative terminal 1-5, the control button 1-6, and the indicator light 1-7 back onto the DC remote control plug 1 to obtain a connector; Step S7: Test the installed connector, and obtain a DC aircraft cable connector after passing the test.

[0023] like Figure 4 , step S5 is specifically as follows: Step S51. Connect the No. 1 control wire core of the DC remote control cable 2 to the No. 1 terminal of the auxiliary terminals 1-4 and the power indicator light to display the on / off status of the power supply; Step S52. Connect the No. 2 control wire core of the DC remote control cable 2 to the No. 2 terminal of the auxiliary terminal 1-4 and the retractable indicator light to display the retractable status of the connector; Step S53. Connect the No. 3 control wire core of the DC remote control cable 2 to the No. 3 terminal of the auxiliary terminal 1-4 and the in-place indicator light to display whether the connector is plugged in place; Step S54. Connect the No. 4 control wire core of the DC remote control cable 2 to the No. 4 terminal of the auxiliary terminal 1-4 and the power button, and press it to control the power supply to be turned on; Step S55. Connect the No. 5 control wire core of the DC remote control cable 2 to the No. 5 terminal of the auxiliary terminals 1-4 and the power-off button, and press it to control the power supply to be disconnected; Step S56. Connect the No. 6 control wire core of the DC remote control cable 2 to the No. 6 terminal of the auxiliary terminal 1-4 and the reeling button, and press it to control the connector to reel; Step S57. Connect the No. 7 control wire core of the DC remote control cable 2 to the No. 7 terminal of the auxiliary terminal 1-4 and the release button, and press it to control the connector to be released; Step S51. Connect the No. 8 control wire core of the DC remote control cable 2 to the No. 8 terminal of the auxiliary terminals 1-4 to form a common line.

[0024] The DC remote control cable of the present invention has a minimum bending radius of 4 times the outer diameter of the cable, and each layer of cable core is separated by a smooth wrapping tape, which is beneficial to relative displacement when the cable is bent. It has been verified through a bending test that the DC aircraft cable connector of the present invention can be bent more than 10,000 times; the present invention adopts a combination of multiple conductive cores to form an energized cable, which reduces the skin effect, and the current carrying capacity is 1.16 times that of an ordinary single cable with the same cross-section.

[0025] Finally, it should be noted that the above specific implementation methods are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to examples, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the spirit and scope of the technical solution of the present invention, which should be included in the scope of the claims of the present invention.

Claims

1. A DC aircraft cable connector, characterized in that: The DC aircraft cable connector comprises a DC remote control plug (1) and a DC remote control cable (2), wherein one end of the DC remote control plug (1) is connected to the DC remote control cable (2); The DC remote control plug (1) comprises a plug socket (1-1), a plug shell (1-2), a positive electrode terminal (1-3), an auxiliary terminal (1-4), a negative electrode terminal (1-5), a control button (1-6), and an indicator light (1-7); the plug socket (1-1) is provided with a plug shell (1-2); the positive electrode terminal (1-3), the auxiliary terminal (1-4), and the negative electrode terminal (1-5) are provided with a plug shell (1-2); and the end of the plug socket (1-1) is provided with a control button (1-6) and an indicator light (1-7); The DC remote control cable (2) comprises a positive core (2-1), a control core group, a filling core (2-3), a wrapping tape (2-4), and a negative core (2-5); a plurality of positive cores (2-1) and a plurality of negative cores (2-5) are wrapped with a wrapping tape (2-4) to form a first cable core group; a filling core (2-3) is provided in the gaps between the plurality of positive cores (2-1) and the negative cores (2-5); a plurality of positive cores (2-1), a plurality of negative cores (2-5), and a plurality of control core groups are arranged outside the first cable core group; two groups of the plurality of control core groups are arranged on both sides of the outer periphery of the first cable core group; a positive core (2-1) and a negative core (2-5) are respectively arranged between the two groups of control core groups; and a second cable core group is formed after the control core group, the positive core (2-1), and the negative core (2-5) are wrapped with a wrapping tape (2-4).

2. The DC aircraft cable connector according to claim 1, characterized in that: The number of auxiliary binding posts (1-4) is 8, and the number of control buttons (1-6) and indicator lights (1-7) are both 4.

3. The DC aircraft cable connector according to claim 1, characterized in that: A sheath (2-6) is arranged outside the second cable core group, and the material of the sheath (2-6) is a low-smoke halogen-free polyolefin material.

4. The DC aircraft cable connector according to claim 1, characterized in that: The control wire core group is composed of a plurality of control wire cores (2-2) which are wrapped with a wrapping tape (2-4) and insulating rubber from the inside to the outside. The material of the filling core (2-3) is carbon fiber, and the material of the wrapping tape (2-4) is a high-strength polyester tape.

5. The DC aircraft cable connector according to claim 1, characterized in that: The outer diameter of the control wire core group is the same as the outer diameter of the positive wire core (2-1) and the negative wire core (2-5).

6. The method for preparing a DC aircraft cable connector according to any one of claims 1 to 5, characterized in that: The following steps are involved: Step S1. pre-cable the control core (2-2) into a control core assembly in a 0+4 structure, then wrap the control core assembly with a wrapping tape (2-4), and then extrude insulating rubber on the outside of the wrapping tape (2-4) through a continuous vulcanization rubber extruder to form a control core group; Step S2. Wrapping a plurality of positive electrode cores (2-1) and a plurality of negative electrode cores (2-5) with a wrapping tape (2-4) to form a first cable core group, wherein the center of the first cable core group is filled with a filling core (2-3); symmetrically cabling a plurality of positive electrode cores (2-1), a plurality of negative electrode cores (2-5) and a control core group, wherein the plurality of positive electrode cores (2-1) and a plurality of negative electrode cores (2-5) are distributed on both sides of the control core group, and wrapping the control core group, the positive electrode cores (2-1) and the negative electrode cores (2-5) with a wrapping tape (2-4) to form a second cable core group; Step S3. Extruding a sheath (2-6) on the second cable core group using a continuous sulfur rubber extrusion machine to obtain a DC remote control cable (2); Step S4. Disassemble the positive terminal (1-3), the auxiliary terminal (1-4), the negative terminal (1-5), the control button (1-6), and the indicator light (1-7) of the DC remote control plug (1), cut the sheath (2-6) of the DC remote control cable (2) with a utility knife, and then connect the plurality of positive wire cores (2-1) to the positive terminal (1-3) of the DC remote control plug (1), and connect the plurality of negative wire cores (2-5) to the negative terminal (1-5) of the DC remote control plug (1), so that the DC remote control plug (1) is connected to the power wire core of the DC remote control cable (2); Step S5. Connecting the DC remote control plug (1) to the control wire core of the DC remote control cable (2); Step S6. Install the positive terminal (1-3), the auxiliary terminal (1-4), the negative terminal (1-5), the control button (1-6), and the indicator light (1-7) back onto the DC remote control plug (1) to obtain a connector; Step S7: Test the installed connector, and obtain a DC aircraft cable connector after passing the test.

7. The method for preparing a DC aircraft cable connector according to claim 6, characterized in that: Step S5 is specifically as follows: Step S51. Connect the control wire core of the DC remote control cable (2) to the No. 1 terminal of the auxiliary terminals (1-4) and the power indicator light to display the on / off status of the power supply; Step S52. Connect the control wire core of the DC remote control cable (2) to the No. 2 terminal of the auxiliary terminal (1-4) and the retraction indicator light to display the retraction status of the connector; Step S53. Connect the control wire core of the DC remote control cable (2) to the No. 3 terminal of the auxiliary terminal (1-4) and the in-place indicator light to display whether the connector is plugged in place; Step S54. Connect the control wire core of the DC remote control cable (2) to the No. 4 terminal of the auxiliary terminals (1-4) and the power button, and press it to control the power supply to be turned on; Step S55. Connect the control wire core of the DC remote control cable (2) to the No. 5 terminal of the auxiliary terminals (1-4) and the power-off button, and press it to control the power supply to be disconnected; Step S56. Connect the control wire core of the DC remote control cable (2) to the No. 6 terminal of the auxiliary terminal (1-4) and the reeling button, and press it to control the reeling of the connector; Step S57. Connect the control wire core of the DC remote control cable (2) to the No. 7 terminal of the auxiliary terminals (1-4) and the release button, and press it to control the connector to be released; Step S58: Connect the control wire core of the DC remote control cable (2) to the No. 8 terminal of the auxiliary terminals (1-4) to form a common line.

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